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Help! Intake manifold issue (long)

Hi everyone. I've been off the board a while. Good to see the usual suspects are still active. Here's the problem. Couldn't pass smog again so checked the archives and one suggestion was to replace the ccv. Since I did have some minor oil leaks I decided to go that route and replace the plugs. I have a mobile mechanic who, up til now, has been a very good, honest and reliable guy. He's worked on all my vehicles and saved me a ton of cash on shop labor. He replaced the 8 plugs no problem but when it came to the CCV, problems came up. Due to a strip bolt he couldn't get the CCV off, so needed to take the whole intake off to get to it. After haggling for an extra $200 for the labor he had the intake off fairly quickly and swapped the CCV. When reinstalling the intake there was one electrical connector at the front of the intake area that he couldn't find the mate to. He seems to think that it was diagnostic connector plug. That worries me. Anyway everythings put together cranks her up and now there's this noticeable intake leak (tested with carb cleaner), no CEL however. He says that I now need to replace the gaskets. I told him I had those replaced 4yrs ago he said just get the parts and he'll take care of me. So I take it for test drive and it's just miserable. The tranny changes gears @ higher revs (could be the new NGK plugs). Returned to the house shut it down and then went out again and barely made it back. It's like in limp mode. Can only get up to 23-35mph and rpm @ 2500 or so with accelerator floored. Any ideas? I really think that connector needs to be plugged to something. Any body have the electrical schematic for the engine bay? Thanks guys for all your help.

Re: JimLev is right 97-98 vs 1999-2003

Sorry 98 540i 6speed non-vanos. I'll try to get a pic when I get home. My mechanic spent a 45 minutes looking for it's mate. It's a black wire about 4-5" long. I recall that one of the inner wires was green. I know that doesn't say much. But I'll try to post a pic ASAP.

Even tho the CEL is not on, check codes anyway..

There may be a pending code, esp. if the engine is running very badly. The code will point to the system that is causing the problem and help in troublshooting.
Ed CT
1998 528i (aka, best car I ever owned!)
5-Speed
Aspen Silver
Aubergine Leather
Zeckhausen CDV
Nokia CK-7
D-Con Cache on Fuel Pump Cover

You can't re-use gaskets, no matter how new>>

they are. I'd dump this gypsy before he screws up your car big-time.

Ypou can find a local BMW indie through bimrs.org, or, if you're lucky enough to have a Checkbook magazine in your town, you can review their surveys.
Ed in San Jose. BMW CCA member since 1987 (Nr. 62319). Golden Gate Chapter. '97 540i 6 speed. Build Date 3/97. Aspensilber over Aubergine leather.

If they are still soft/flexible and retain their (

original shape I have reused them. My IM gaskets are ~3 years old, when I pulled the IM last Sept I reused the old gaskets, they sealed just fine. I'd never reuse water pump, head gaskets, or ones that were responsible for holding back pressure.

Wire colors? Red/White and Blue/Green?

"Drive It Like You Stole It, A Sickness for Quickness"The Bottle Rocket "King of Spray" 2 Stage Nitrous OxideDare to be different and stand out among the crowd of me-to-cars!No guts, no glory!Tire smoke, not traction control!Zionsville all aluminum radiator to replace the 3 leak prone Nissens Radiators!

Yes!!!! What's it for?

It connects to the seconday (electronic) throttle

It's the connector right in front of it, in your pictures, on the aluminum elbow. Whenever I have connectors that I can't figure out I just try to connect them to anything that they will reach. Very few electrical connectors on a BMW will connect to the wrong thing.

The secondary throttle is part of the ASC system and is a second throttle plate in front of the actual throttle. It closes when wheelspin can't be slowed enough by the rear brakes.

I don't think it has anything to do with you new symptoms. The intake gaskets are easy to get out of place. They are hard rubber donuts and are either seated or not. You should also check the operation and gasket around the Idle control Valve. Which is the cylinder underneath your picture of the loose connector.
Vin
98 540 Sport with everything & extra hots
BMW CCA, Boston Chapter
"The 540 is the head-case supermodel girlfriend..." Eric S.
"The worst thing you could do with your money is save it." ~ Jackie Gleason
If everything seems under control, you're just not going fast enough. Mario Andretti
The United States is a nation of laws: poorly written and randomly enforced. - Frank Zappa

Thanks Vin but it does need to be connected right?

My mechanic was doing the same thing. Trying to see how far it reaches to figure out where it could possibly be connected. Based on the condition of the connector, it seemed unused. That's why he thought it was a diagnostic plug. Flooring the throttle and getting little power wouldn't that be related to this plug being disconnected?

It should be yes, but I don't think it's the prob.

Double check the throttle linkage and cable. It's possible the mechanic miss-routed it. Check for intake air leaks around the Idle Air Valve too.
Vin
98 540 Sport with everything & extra hots
BMW CCA, Boston Chapter
"The 540 is the head-case supermodel girlfriend..." Eric S.
"The worst thing you could do with your money is save it." ~ Jackie Gleason
If everything seems under control, you're just not going fast enough. Mario Andretti
The United States is a nation of laws: poorly written and randomly enforced. - Frank Zappa